Urban Cargo

Searching alternative solutions for ecological urban transportation

The urban sphere is undergoing a significant transformation. Automotive mobility is transitioning towards more autonomous and cleaner practices. Public transport is simultaneously improving, expanding, and in some instances, fares are even becoming free. Ecological awareness is driving a change where roads are turning into vehicle-free zones, and entire city districts are kept clear of cars with high pollutant emissions. At the same time, entirely new mobility modes are emerging, giving rise to novel means of transportation, along with new challenges regarding their design and production.

The Cologne-based CNC carpentry, Bächer Bergmann GmbH, specializes in the manufacturing of transport boxes for various logistics and transport companies using diverse types of bicycle-based vehicles. With the growing demand for sustainable, clean, reliable, and fast urban delivery systems, the need for unique solutions is also escalating. Food supply, the transportation of children, trash removal, battery swapping for e-scooters, taxis, and the delivery of post, packages, and cargo – all have specific requirements.

However, the bulk of existing products are mass-manufactured and often unable to meet specific requirements regarding size, safety, and adaptability. While the transportation of the requested items is largely carbon-neutral, the materials used in the making of these systems are often not. This situation creates a contradiction with the ecological claims these companies make.

In partnership with Bächer Bergmann GmbH, the aim of this course was to develop innovative designs for transportation containers, establish customizable processes for robotic or similar digital manufacturing methods, and identify materials that meet the necessary requirements. The containers should be extremely lightweight, durable, water and weather-resistant, and shock-resistant. They should also be easy to repair, biodegradable, sustainable, or recyclable, and, if possible, fit the size of a euro-pallet (80 x 120 cm). This project presents a substantial step towards innovative, sustainable, and adaptable urban transportation solutions.

Institute
Dessau Department of Design

Students
Tong Pan, Judy Elkhatib, Mallika Manchanda, Karl Breitling, Willy Axt, Toni Pasternak

Supervision
Prof. Dr. Manuel Kretzer

Collaborator
Bächer Bergmann GmbH

Project Date

2021

Category

Biomaterials · Digital Fabrication

Recycled Plastic Boxes
Based on preliminary research into recycled plastic materials, Tong Pan proposed a cargo box based on the features of recycled plastic combined with nylon tarpaulin to create a box with an open-top design. The overall dimensions are set at 80cm x 80cm x 120cm, in line with the courier company’s (DHL) stipulations that the longest side of a normal parcel should not exceed 120cm. However, there are often special, larger parcels that need transportation. The open-top design accommodates such situations effectively.

The whole case is made of four recycled plastic panels and a nylon tape held together by hinges. This means that whichever part is broken, it can be repaired and replaced very quickly. The box has six quick buckles to hold the tapes in place and the courier can use the buckles for different situations, for example if the shipment is small there is no need to fasten the top two buckles. There are total of four holes on both sides of the box. Not only for fixing the tape, but for example two straps can be also set when the box is open. This will prevent the big packages from falling out the box. Switching between the two states is very simple. Just unfasten the buckle and roll up the cover, and then fix it.

Bio-Composites
The concept of Willy Axt centers around exploring the potential of bio-composites, particularly for their application in the transportation sector. Natural fibers and bio-resins are identified as promising materials due to their environmental sustainability, mechanical strength, and manufacturing compatibility. A key area of exploration was replacing conventional epoxy resins with bio-based alternatives, such as bio-based DGEBA, sourced from non-petrochemical inputs. The project also investigated the use of various natural fibers, including wheat-straw, rye-straw, sisal, and hemp, all of which offered unique advantages and challenges in terms of crop seasonality, cost, and fiber performance.

The project encompassed a detailed examination of manufacturing methods, particularly resin-transfer-molding, to create bio-composite structures. Design considerations also played a central role, with attention paid to form, functionality, and the unique aesthetic qualities of unfinished bio-composites. A series of 3D form studies were conducted to visually demonstrate these design possibilities. In the final phase a cargo box was designed, catering to specific needs such as large capacity, water resistance, lightweight structure, and ease of repair. This involved utilizing recycled plastic in combination with nylon tarpaulin, resulting in a durable and environmentally-conscious product that effectively showcases the potential of bio-composites.

Mycelium Cargo Box
This concept by Karl Breitling wants to harnesses the power of mycelium, the extensive, subterranean part of a fungus, to create a sustainable, solid composite material. The project seeks to redefine the way we perceive and use materials, turning to nature’s most efficient recyclers, fungi, for inspiration. Mycelium’s capability to convert dead biomass into its own and bind loose material, combined with the right ingredients and growing conditions, can be utilized to develop eco-friendly alternatives to conventional materials. The box’s design emphasizes not only functionality but also aesthetics, featuring two approaches: a stable skeleton structure for optimal transportation, and a design that reflects the natural root structure of mycelium. This unique combination of natural inspiration and technology offers an unprecedented outlook on material research and product design, foregrounding sustainability and the interconnectedness of nature and man-made structures.

Accordeon Cargo Box
The idea of Judy Elkhatib focuses on three materials: Fiber Reinforced Plastic (FRP), Polyethylene (PE), and Compressed Strawboard. FRP is a composite material offering weight saving, strength, and durability. It is also cost-effective compared to other materials with similar properties. PE is a versatile plastic polymer known for its durability and weather resistance. The Compressed Strawboard is an innovative material made from 100% agricultural waste. It has a high strength-to-weight ratio and resistance to warping, water, and fire, making it a perfect fit for the project.

By applying kerfing techniques, the Compressed Strawboard is transformed into a flexible enough material to allow the container to expand and contract, giving it a unique and versatile shape. This retractability indicates the capacity of the container, allowing people to identify whether the delivery process is in progress or nearing completion. The container’s design maintains sustainability, offers playful marketing opportunities, and supports the ecological claims of the companies involved.

Institute
Dessau Department of Design

Students
Tong Pan, Judy Elkhatib, Mallika Manchanda, Karl Breitling, Willy Axt, Toni Pasternak

Supervision
Prof. Dr. Manuel Kretzer

Collaborator
Bächer Bergmann GmbH

Project Date

2021

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